Total Quality Management

Innovative Project

On
Reducing welding defects using six sigma
Techniques, A Review

Submitted By:
Name- D Rishi Kumar
Roll Number- 2K19/PE/020
Name- Abhishek Trikoti
Roll Number- 2K19/PE/006

Delhi Technological University

Shahbad Daulatpur, Main Bawana Road, Delhi – 110042
 Table of Contents

TABLE OF CONTENTS

CHAPTER PAGE

COVER PAGE................................................................................................................................................1

TABLE OF CONTENTS...................................................................................................................................2

ABSTRACT....................................................................................................................................................3

INTRODUCTION...........................................................................................................................................4

LITERATURE REVIEW....................................................................................................................................5

METHODOLOGY...........................................................................................................................................7

RESULTS AND DISCUSSIONS.........................................................................................................................9

CONCLUSION.............................................................................................................................................10

REFERENCES..............................................................................................................................................11
 Abstract

Through a review study, this review paper analyses the quality

and productivity improvement in a manufacturing firm. The

study examines a Six Sigma DMAIC (Define-Measure-

Analyze-Improve-Control) application in an industry, which

provides a framework for identifying, quantifying, and

eliminating sources of variation in an operational process in

order to optimise the process yield with well-executed

operation variables, enhance and quality performance control

strategies Six Sigma enhances the critical process

performance (process yield). The operational process

improves resource use, reduces variation, and maintains

consistency, a steady level of quality process output. This

paper analyses the main causes of failure in a welding process

at a manufacturing plant and proposes that the problem be

solved using the Operational Six Sigma technique.

 Introduction

To respond to the challenges given by the competitive

business environment, most industrial and service firms have

adopted Total Quality Management (TQM) as a strategic

approach. TQM has evolved into a comprehensive

management strategy based on continuous improvement and

organization-wide participation, with a primary focus on

quality. TQM has culminated in Six Sigma, which aims for a

defect-free production rate of 99.99927 percent. TQM has

evolved into a comprehensive management strategy based on

continuous improvement and organization-wide collaboration,

with a primary focus on quality. TQM is a method of instilling

quality awareness at every stage of manufacturing or service,

with the end consumer in mind.

 Literature Review

Year Author Paper Title Main findings

2013 Shashank Soni Reduction of Welding defect using six Six Sigma is an
sigma technique effective way to find
out where the greatest
process needs are and
which the softest points
of the process are
2014 Nicole C Anderson Reducing Welding defect in Turnaround Six Sigma can be
& Jamison V Project using six sigma applied in service
kavoch based industry. It also
provides evidence of
the tangible benefits
that can be achieved
within specialty
construction operations
using process
improvement
strategies.
2016 Amit Yadav & V K Quality Improvement by using six sigma Rejection of Clutch in
Sukhwani DMAIC in an Industry automotive industry
was brought down by
successful
implementation of
DMAIC
2014 Tejaskumar S A Review: Six sigma implementation Six Sigma can be
Prasana, Dr practices in Indian Manufacturing SMEs applied in small and
Darshak A Desai large companies,
DMAIC has been
applied in each and
every step of
construction activity to
reduce waste and
improve efficiency
2017 Preetam Singh Six Sigma in Construction Industry More case studies have
Negi, Akash been conducted as
Mandaliya compared to empirical
and conceptual studies
2008 Tushar N Desai & Six Sigma : A new direction to Quality The six sigma based
Dr R.L Shrivastava and Productivity Management methodology has been
used to optimize the
variables of SAW
Boom machine
 operational Process
2014 Mr. Mahesh S Reduction in TIG welding defect for Lack of fusion is most
Shinde, Dr. K.H. productivity improvement using six risky defect in TIG
Inamdar sigma welding with MDN
250 materials and
improper shielding is
also a serious issue
while welding
2019 Muhammad Optimization in MIG Welding by Using using six sigma
Mudassar Sharif , Six Sigma Tools reduced the defect rate
Zahid Anwar, up to 25% operating
Yousaf Ayub, cost and customized
Amar Abbas and the sigma level from 2
Munir Ahmed to 4 sigma

2021 Adesh Thavre, Dr. Reduction in Welding Defects by The DMAIC

[Link] Implementing Six Sigma Techniques methodology reduces
the welding defects and
time required to
complete the auxiliary
piping

2012 Megan Florent Process and Quality improvement A composite steel-

Tchidi, Zhen he using Six Sigma in construction concrete model has
and Yan Bo Li industry been developed using
DMAIC and ANSYS
for scientific and
economical use in
construction industry

Methodology
The DMAIC Six Sigma Methodology

The DMAIC is a fundamental part of Six Sigma technique,

which is a better way to enhance work processes by lowering

fault rates in the completed product. The DMAIC approach is

a way for analysing data, there are five steps to this project:

define, measure, analysis, improvement and control.

Define Phase

In this phase, define the purpose of project, scope and process

background for both internal and external customers.

Process Deliverables

1. Reduction of non-production idle hours

2. Reduction of COPQ

3. Increase in welding machine process yield

 Measure Phase

This phase presents the detailed process mapping,

operational definition, data collection chart, evaluation of

the existing system, assessment of the current level of

process performance, etc.

Operational Definition

welding machine process is defined as the ratio of net

operating hours to gross available hours

Type of Data

The type of data is continuous (variable)

welding Process= Net operating hours/ Gross available hours.

Control Phase

Tangible benefits
 1. Savings

2. Rework of defect trend is in decreasing

Intangible benefits

1. Improved customer satisfaction

2. Reduced possibility of failure

3. Improved availability

4. Closure of potential failure mode

Results and Discussion

Six sigma is a powerful tool for determining where the

most pressing process demands are and where the

process's weakest areas are. In addition, six sigma

provides quantifiable indicators and sufficient data for

analytic purposes.

The achieved results are :

 Reduced possibility of failure

  Reduced costs of poor quality

 Reduced labour expenses

 Improved customer satisfaction

 Closure of potential failure mode

 Production time reduction

 Index cost/volume reduction

Definitely, Six Sigma is a powerful methodology that

can, if properly implemented, result in significance

savings and improvements.

Conclusion

To handle the variance problem in a welding process, the

operational Six Sigma methodology was chosen. The

review proposes a real-time monitoring method for

removing the weld's shear strength without destructive

resting.
This six sigma improvement methodology, namely, the

DMAIC project, demonstrates that the company's

performance has improved in terms of: increased

customer satisfaction (both internal and external),

adherence to delivery schedules, development of specific

methods to redesign and reorganise a process with the

goal of reducing or eliminating errors and defects;

development of more efficient, capable, reliable, and

consistent manufacturing processes, and more.

Six Sigma equips company leaders and executives with

the strategy, methodologies, tools, and strategies they

need to transform their businesses.

Six Sigma has long been acknowledged as a critical

corporate technique for establishing and maintaining

operational (process) effectiveness, resulting in

significant cost savings and, as a result, achieving

 organisational excellence. Six Sigma may propel

industries to the forefront of global competition if

properly implemented with entire commitment and

focus.

References

Soni, S. (2013). Reduction of welding defect using six sigma technique. International
Journal of Mechanical Engineering and Robotics Research, 404–412.

Anderson, N. C., & Kavoch, J. V. (2014). Reducing welding defect in turnaround project
using six sigma. Quality Engineering.

Yadav, A., & Sukhwani, V. K. (2016). Quality Improvement by using six sigma DMAIC in
an Industry. International Journal of Current Engineering and Technology, 41–46.

Prasana, T. S., & Desai, D. A. (2014). A Review: Six sigma implementation practices in
Indian Manufacturing SMEs. IJERA Journal, 663–673.

Negi, P. S., & Mandaliya, A. (2017). Six Sigma in Construction Industry. International
Journal of Productivity and Quality Management.

Desai, T. N., & Shrivastava, R. L. (2008). Six Sigma : A new direction to Quality and
Productivity Management.

Shinde, M. S., & Inamdar, K. H. (2014). Reduction in TIG welding defect for productivity
improvement using six sigma. International Journal of Technical Research and
Applications, 100–105.

Sharif, M. M., Anwar, Z., Abbas, A., & Ahmed, M. (2019). Optimization in MIG Welding by
Using Six Sigma Tools. Industrial Engineering & Management, 1–9.

Thavre, A., & Nagare, M. R. (2021). Reduction in Welding Defects by Implementing Six
Sigma Techniques. International Journal of Research Publication and Reviews, 1007–
1011.

Tchidi, M. F., he, Z., & Li, Y. B. (2012). Process and Quality improvement using Six Sigma
in construction industry. Journal of Civil Engineering and Management .